Box insert

ABSTRACT

A product is secured within a box, using an apparatus that can be re-used to secure a different sized or shaped product. The apparatus is a box insert having a rigid sheet that fits snugly within the box, and multiple supports mounted on both the top and bottom of the rigid sheet. The supports mounted on the top side of the insert are spaced in an opposing manner to hold a first product snugly between those supports, while the supports mounted on the bottom side are spaced to hold a second product of a different shape or size. The insert is placed in a box so that either the top side or the bottom side of the insert is closest to the top of the box to serve as a support for whichever sized and shaped product best fits within the supports on that top-facing side of the insert.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a specialized insert to be placed in a generally rectangular box to enable a single product from a set of products with a variety of shapes and sizes to be safely secured within the box.

2. Description of the Prior Art

Rectangular boxes are advantageous for storing and transporting many different products. Since boxes with a rectangular shape are more economical to produce and easier to stack and transport than boxes of other shapes, products of many different shapes are fit into such a standard box. It is important to properly cushion non-rectangular products within a box, to prevent damage due to pressures which may be applied to the box during transport, such as when the box is dropped or when another box is stacked on top of it. Even when rectangular shaped products are transported in a rectangular box, the box may be somewhat bigger than the product in one or more dimensions, providing opportunities for the product to shift and be damaged during transit. In order to protect an enclosed product from damage due to being bounced around within a moving box, specialized inserts are typically devised to support a product in a safe place within the box, while providing cushioning from blows to the box.

Thus, it is well known in the prior art to construct an insert, typically of cardboard or foam or some combination thereof, the exterior sides of which fit snugly against the interior walls of a rectangular box, but the interior walls of which are specially shaped to snugly fit around a particular product to be shipped in the box. Such inserts allow products of many different sizes and shapes to be safely shipped in generally rectangular boxes. Typically, once the product arrives at its destination, the insert is thrown into the garbage.

To enable box inserts to be used multiple times, and thus avoid the waste of disposing of an insert after a single use, it is advantageous to utilize an insert that can be used to protect and safely ship products of more than one shape or size. A particular example of this general concept provided the challenge that led to the invention of the insert claimed herein. Electronic equipment used in homes to receive internet service or cable service may need to be upgraded from time to time. In these cases, it is frequently efficient to use a common carrier to deliver a new piece of equipment which can typically be installed by the consumer. It may be useful to return the old piece of equipment which is being replaced to the company which supplied the new equipment, to allow the returned unit to be reconditioned and re-used. Although the box in which the new equipment is delivered is a convenient possible container to ship the old equipment back, the insert designed to safely hold the new equipment is unlikely to also fit the old equipment that needs to be shipped back.

The claimed insert is designed to fit one product, such as a new piece of electronic equipment, when the insert is fit into a box with the top side of the insert in an upwards position. By simply flipping the insert over, a different size and shape product, such as the old electronic equipment being replaced, can be securely held on top of the same insert oriented in an inverted position within the same box. An accessory opening in the middle of the insert allows accessories such as a cable or remote control device to be slipped under the insert for transport.

By using the insert with its specialized capability of safeguarding and holding products of more than one size and shape within a box, the insert and the box in which it is placed are more likely to be re-used, avoiding the waste and disposal problems associated with using a new insert for each product. Furthermore, using one insert for multiple products results in cost savings as fewer inserts are needed to be manufactured and stored to safely ship the same number of various-shaped products.

SUMMARY AND OBJECTS OF THE INVENTION

A primary object of the present invention is to provide a box insert which will allow a single product from a set of multiple products of different sizes and shapes to be safely stored and transported within the same box. The insert can be repeatedly used to accommodate more than one shaped product, thus alleviating the waste of inserts which are typically thrown out after a single use.

Another object of the present invention is to provide such an insert which can be easily used without training or complicated instructions. Simply by turning the insert upside down, a different product may be safely held in a cushioned position on the top-facing side of the insert to avoid damage during transport within the same box.

Another object of the present invention is to provide such an insert which provides a secure area for accessories such as remote control devices and cables to be shipped in a box containing a related product.

These objects are achieved by a specialized box insert having a substantially flat, rectangular and rigid base component to which supports are attached to provide multiple different secure areas of different shapes and sizes. Although the rigid component and supports can be made from a variety of different materials, corrugated cardboard is an ideal material from which to economically make a sturdy rigid sheet, while foam is an ideal material from which to economically make supports which will securely hold a product in place while providing cushioning to protect the product.

The rigid sheet should fit from side to side within a rectangular box which is sufficiently large to accommodate the largest of the multiple products to be carried in the box. The length and width of the rigid sheet of the insert are beneficially designed to fit snugly within the box when the rigid sheet is parallel to the bottom of the box. In this manner, the rigid sheet is snugly held in a desired place within the box.

Supports are strategically placed on the top side of the rigid sheet to accommodate one or more products of a particular size and shape, and are similarly placed on the bottom side of the rigid sheet to accommodate a different product or products. In this manner, the same insert can be used to support and safeguard more than one size and shape of product, depending on whether the insert is placed in the box with the top side facing up or the bottom side facing up. The supports mounted on whichever side of the rigid sheet is closest to the bottom of the box provide cushioning between the bottom of the box and the insert, while the insert holds a product in a secure position between the insert and the top of the box.

When the primary product to be supported by the insert is substantially rectangular, supports will typically be placed near opposite ends of the length of the top side of the rigid sheet and at opposite ends of the width of the top side of the rigid sheet, to create an area between the four supports into which the primary product can snugly fit. A different sized alternate product can easily be accommodated by the bottom side of the same insert by placing opposing supports on the bottom side of the rigid sheet to accommodate the length of the alternate product, and placing opposing supports on the bottom side of the rigid sheet to accommodate the width of the alternate product, to create an area matching the size of the alternate product to be supported by the bottom side of the insert. Thus, the insert can be inverted to enable the alternate product to be supported by the bottom side of the insert when it is desirable to use the insert to support the alternate product instead of the primary product.

Still other products with other shapes and sizes can be supported by the same insert. Products with different lengths and widths can be supported by the same side of the insert by using a support that contains a base support at one distance from an opposing support and support extensions on either end of the base support that are a different distance from the opposing support. In these cases, the base support is beneficially designed so that the width of the product which has a length extending to the base support snugly fits within the support extensions extending from either end of that base support.

Ideally, an accessory opening is formed in the rigid sheet to allow accessories, such as cables or remote control devices, to be inserted through the accessory opening so that the accessories may be carried in the box beneath a product supported by the insert. A variety of shapes and sizes, including octagons, pentagons, circles, and rectangles, are possible for the accessory opening. Yet another example would be an accessory opening with a U-shaped side suitable for receiving a round accessory such as a coiled cable, and an opposite straight edge suitable for receiving a substantially rectangular accessory such as a remote control device. An octagonal accessory opening has proven to be particularly flexible for receiving a variety of accessories, without harming the structural integrity of the insert. Additional openings may be formed in the rigid sheet to provide a receptacle for protuberances such as supporting feet which extend from the bottom of the product supported by the insert.

In this manner, the insert of the present invention provides an economical and easy-to-use support which can hold one of multiple products in a secure position within a box during storage and transit, with a single insert providing potential support for multiple products having different sizes and shapes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective top and side view of a box that has been cut away to view an insert according to the present invention.

FIG. 2 is a top view of an insert, according to the present invention.

FIG. 3 is a bottom view of the insert of FIG. 2.

FIG. 4 is a top view of the top side of an insert of the present invention, holding a primary product.

FIG. 5 is a top view of the top side of the insert shown in FIG. 4, shown holding an alternate product.

FIG. 6 is a top view of the bottom side of the insert shown in FIGS. 4 and 5, which insert has been inverted to hold yet another alternate product.

FIG. 7 is a top view of an insert of the present invention on which supports have been attached in a continuous fashion to snugly hold a non-rectangular product.

FIG. 8 is a top view of a top side of an insert of the present invention, showing a moveable support positioned in a first position.

FIG. 9 is a top view of the top side of the insert shown in FIG. 8, with the moveable support positioned in a second position.

FIG. 10 is a perspective top and side view of a box that has been cut away to view an insert according to the present invention shown with accessories, having been placed through an accessory opening, being held under the insert.

In the drawings, the following legend has been used:

10 Insert

11 rigid sheet of insert

12 top of rigid sheet

13 bottom of rigid sheet

14 width end of rigid sheet

15 length end of rigid sheet

16 length of rigid sheet

17 width of rigid sheet

18 box

19 primary product

20 length of primary product

22 width of primary product

24 depth of primary product

28 alternate product

30 length of alternate product

32 width of alternate product

35 support

36 top support

37 bottom support

38 depth of support

39 top length support

40 top width support

41 bottom length support

42 bottom width support

43 distance between opposing supports

46 base support

47 end of base support

48 accessory opening in insert

51 scored area surrounding insert opening

52 cuts in area surrounding insert opening

53 protuberance opening in insert to receive foot of equipment

54 fixed support extension

56 movable support extension

58 distance between opposing support extensions

60 hinge on movable support extension

DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention concerns a method and apparatus for holding and protecting a product within a rectangular box. As shown in FIG. 1, the apparatus consists of a specialized insert 10, which may be used to secure a product 19 within a box 18, and which can be reused to secure another product 28 of a different shape and size than the first product 19. The method consists of simply positioning the insert 10 within the box 18 so that a top side 12 or a bottom side 13 of the insert 10 faces upwards, depending on which side best accommodates the size and shape of the product 19, 28 to be held within the box 18.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced without these specific details. Some well-known methods and structures have not been set forth in order not to unnecessarily obscure the description of the present invention.

The device 10 for holding and protecting a product 19, 28 within a box 18 includes a substantially flat, rectangular, and rigid sheet 11 to which supports 35 have been attached, as shown in FIG. 2. The rigid sheet 11 can advantageously be made of any substantially rigid material, such as cardboard or other corrugated materials. The supports 35 can advantageously be made of any material which will provide stability and cushioning to a product 19 being held within the box 18, such as foam. The length 16 and width 17 of the rigid sheet 11 ideally fits snugly within the sides of the box 18 so that the rigid sheet 11 maintains a stationery position within the box 18, as shown in FIGS. 1 and 10, despite possible forces acting on the box 18 during transit or storage.

Supports 36 are mounted on the top side 12 of the rigid sheet 11, as shown in FIG. 2, in a manner different than supports 37 are mounted on the bottom side 13 of the rigid sheet 11, as shown in FIG. 3. As a result, products of different sizes and shapes 19, 28 can be held between the top of the box 18 and whichever side of the rigid sheet 12, 13 is in a upwards position. The configuration of the supports illustrated in the accompanying figures is merely one of many possible such configurations. The configuration of supports 35 will be chosen to fit snugly around a particular product 19 to be held in place on the insert 10. Opposing length supports 39 can beneficially be mounted on the top side 12 of the rigid sheet 11 near the two length ends 15 of the rigid sheet 11, as best shown in FIG. 4. Opposing width supports 40 can be attached to the top side 12 of the rigid sheet 11 near the two width ends 14, as also shown in FIG. 4. In this manner, an area between the four opposing supports 39, 40 is created that corresponds to the length 20 and width 22 of the primary product 19 to be held between the supports 39, 40.

Similarly, supports 37 are mounted on the bottom side 13 of the rigid sheet 11 to snugly fit around the length 30 and width 32 of an alternate product 28, as shown in FIGS. 3 and 6. The distance 43 between opposing length supports 41 mounted to the bottom side 13 of the rigid sheet 11 should be approximately the same as the length 30 of the alternate product 28, and the distance 43 between opposing width supports 42 mounted to the bottom side 13 should be approximately the same as the width 32 of the alternate product 28. Similarly, the depth 38 of each support 35 is generally equal to or less than the depth 24 of each product 19, 28 to be secured by the supports 35, as best shown in FIG. 1. In this manner, a product 19, 28 can be held securely between opposing supports 35 which have been positioned on the insert 10 so as to create an area between the opposing supports 35 that snugly accommodates a particular product 19, 28.

Still other alternate products 28 can be held securely by the same insert 10 by providing specialized supports 35 with a base 46 and an extension 54, as shown in FIGS. 2 and 5. While a primary product 19 may be fit longitudinally on one side 12, 13 of the insert 10 between opposing length supports 39 as shown in FIG. 4, an alternate product 28 may be fit securely on top of the same side 12, 13 of the insert 10 when oriented perpendicular to the primary product 19, as shown in FIG. 5. As shown in FIG. 2, the extensions 54 of opposing supports 36 are advantageously spaced apart from each other a distance 58 corresponding to one dimension 20, 22 of primary product 19, while opposing base supports 46 are mounted with a distance 43 between them so that the base supports 46 fit snugly against sides of alternate product 28. As best shown in FIG. 4, the extensions 54 ideally extend from each end 47 of each base support 46 to provide an area between extensions 54 on the same side of the insert 10 which is suitable for snugly holding an alternate product 28 with width 32.

Further flexibility in securing a variety of shapes and sizes of products 19, 28 can be achieved by using supports 35 with a fixed base 46 and a moving support extension 56, as shown in FIGS. 8 and 9. Each moving support extension 56 is connected to a base support 46 by a hinge 60, as best shown in FIG. 9, allowing the support extension 56 to be moved between multiple positions to fit against a variety of shaped products 19, 28.

It is possible to configure the various supports 35 in an unlimited number of different ways, to snugly support products of many different sizes and shapes. For example, an irregularly shaped product 28 as shown in FIG. 7 may best be supported by a continuous insert 36 surrounding the product 28

One or more openings 53 may be made in the rigid sheet 11 to accommodate protuberances (not shown), such as feet extending below a product 19, 28, when the main body of the product rests on the insert 10.

An accessory opening 48 may beneficially be formed in the rigid sheet 11 as best shown in FIGS. 8 and 10. The shape of the accessory opening 48 advantageously corresponds to the shape of auxiliary items to be carried in the box 18. For example, if an electronic product 19 is to be secured by the insert 10 within the box 18, accessories such as a coil of cable or rectangular remote control device may be safely received into the area beneath the insert 10 by placing those items through the accessory opening 48. In this case, the shape of the accessory opening may ideally be an octagon which will accommodate a circular coil of cable or a rectangular remote control device, as best shown in FIG. 10. A scored area 51 surrounding the accessory opening 48 may be created by making straight cuts 52 in that area extending outward from the opening 48, and by forming creased lines on the exterior of the area 51 opposite the opening 48. In this manner, the scored area 51 may be easily pushed downward to more conveniently receive accessories through the opening 48. By advantageously forming the accessory opening 48 in an octagonal shape, the rigid sheet 11 retains sufficient structural integrity to cause the scored area 51 to resume its original position after being pushed down to receive an accessory.

Thus, the present invention provides an insert which can be reused multiple times, each time securing a product from a set of products of different sizes and shapes within the same box for storage or transport. The method of securing each product is simply to orient the insert in the appropriate direction to place upwards a side of the insert with supports matching the size and shape of the product to be secured in the box, so that the product can be snugly held on top of the insert by those supports. Supports mounted on the opposite side of the insert may rest against the bottom of the box to provide cushioning and support.

Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is purely illustrative and is not to be interpreted as limiting. Consequently, without departing from the spirit and scope of the invention, various alterations, modifications, or alternative applications of the invention will, no doubt, be suggested to those skilled in the art after having read the preceding disclosure. Accordingly, it is intended that the following claims be interpreted as encompassing all alterations, modifications, or alternative applications as fall within the true spirit and scope of the invention. 

1. An insert to be placed in a substantially rectangular box having opposing parallel sides perpendicular to a flat bottom, which insert supports and protects a product to be transported within the box, comprising: a. a substantially flat, rectangular, and rigid sheet having a top side and a bottom side, b. said rigid sheet having two opposing width ends that establish a width of said rigid sheet and two opposing length ends that establish a length of said rigid sheet such that said rigid sheet snugly fits within the box when said rigid sheet is substantially parallel to the bottom of the box, c. a plurality of top supports attached to said top side of said rigid sheet in an opposing manner to form a first desired area between said top supports suitable for snugly holding a first product having a first size, d. a plurality of bottom supports attached to said bottom side of said rigid sheet in an opposing manner to form a second desired area between said bottom supports suitable for snugly holding a second product having a second size different from said first size of the first product, and e. an accessory opening formed in said rigid sheet suitable for receiving an accessory to be stored beneath the product supported on said rigid sheet.
 2. An insert according to claim 1, wherein: a. said top supports comprise at least two top length supports secured to said top side of said rigid sheet proximate to opposing length ends with a first desired length distance between said top length supports and at least two top width supports secured to said top side of said rigid sheet proximate to opposing width ends with a first desired width distance between said top width supports, and b. a first product to be transported within the box fits snugly between said top length supports and said top width supports.
 3. An insert according to claim 2, wherein a. said bottom supports comprise at least two bottom length supports secured to said bottom side of said rigid sheet proximate to opposing length ends with a second desired length distance between said bottom length supports and at least two bottom width supports secured to said bottom side of said rigid sheet proximate to opposing width ends with a second desired width distance between said bottom width supports, and b. a second product to be transported within the box fits snugly between said bottom length supports and said bottom width supports.
 4. An insert according to claim 1, wherein at least one of said top supports further comprises a base support with two ends and support extensions extending from each end of said base support toward an opposing top support, so that said first product snugly fits between said base support and said opposing top support, and a third product snugly fits between said support extensions and said opposing top support.
 5. An insert according to claim 4, wherein at least one of said support extensions is connected to said base support by a hinge permitting said support extension to be movable between a plurality of positions.
 6. An insert according to claim 1, wherein at least one of said bottom supports further comprises a base support with two ends and support extensions extending from each end of said base support toward an opposing bottom support, so that said second product snugly fits between said base support and said opposing bottom support, and a fourth product snugly fits between said support extensions and said opposing bottom support.
 7. An insert according to claim 6, wherein at least one of said support extensions is connected to said base support by a hinge permitting said support extension to be movable between a plurality of positions.
 8. An insert according to claim 1, wherein said top supports are connected to each other to form a single connected support surrounding said first desired area suitable for snugly holding a first product.
 9. An insert according to claim 1, wherein said bottom supports are connected to each other to form a single connected support surrounding said second desired area suitable for snugly holding a second product.
 10. An insert according to claim 1, wherein said accessory opening has an octagonal shape suitable for receiving a substantially round accessory.
 11. An insert according to claim 1, wherein a scored area surrounding said accessory opening is scored with cuts extending outward from said opening so that said scored area may be pushed downward as an accessory is placed through said accessory opening and said scored area substantially returns to an original position adjacent to said accessory opening after the accessory is placed beneath the insert.
 12. An insert according to claim 1, further comprising a plurality of protuberance openings formed in said rigid sheet suitable for receiving protuberances from a product to be transported in the box.
 13. A method of protecting a product to be transported within a substantially rectangular box having opposing parallel sides perpendicular to a flat bottom, comprising the steps of: a. Placing within the box an insert having a substantially flat, rectangular, and rigid sheet with a top side, a bottom side, two opposing width ends that establish a width of said rigid sheet, two opposing length ends that establish a length of said rigid sheet, a plurality of top supports attached to the top side of said rigid sheet in an opposing manner to form a first desired area between said top supports which top supports are suitable for snugly holding a first product having a first size, a plurality of bottom supports attached to said bottom side of said rigid sheet in an opposing manner to form a second desired area between said bottom supports which bottom supports are suitable for snugly holding a second product having a second size different from said first size of the first product, and an accessory opening formed in said rigid sheet suitable for receiving an accessory to be stored beneath the product supported on said rigid sheet, b. orienting said rigid sheet so that the top side of said insert is proximate to the flat bottom of the box if the product to be protected snugly fits within said second desired area or orienting said rigid sheet so that the bottom side of said insert is proximate to the flat bottom of the box if the product to be protected snugly fits within said first desired area. 